Method of manufacturing composite vehicle panels

ABSTRACT

A method of fabricating composite vehicle panels includes the steps of forming a first, upper panel having a depending peripheral lip, forming a second, lower panel of laid up woven mat or strips of a fibrous material such as fiberglass or carbon fibers and a plastic resin to form a corrugated panel having a depending peripheral lip, placing an adhesive on the raised portions of the corrugations and the peripheral lip of the second panel and securing the panels together at the corrugations and about their peripheral lips.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of Application Ser. No. 10/748,401,filed Dec. 30, 2003 now U.S. Pat. No. 7,163,253, entitled Method ofManufacturing Composite Vehicle Panels, the entire disclosure(s) ofwhich is/are incorporated herein by reference.

BACKGROUND OF THE INVENTION

The invention relates generally to a method for manufacturing acomposite panel and more particularly to a method of fabricating andassembling composite panels for use on motor vehicles such as pickuptrucks, crossover vehicles, SUV's and the like.

The continuing popularity of pickup trucks and crossover vehicles havinga passenger compartment smaller than an SUV but also including a truckbed has created a growing market for accessories for these vehicles. Oneof the most popular accessories is a closure or tonneau cover for thetruck bed. Characterized most simply, the tonneau cover is ahorizontally disposed structure which covers the truck bed and engagesand is supported by the rails of the truck bed.

There the simplicity ends because this seemingly utilitarian device issubject to many structural and operational requirements. First of all,the closure or tonneau cover must generally not be stationary but mustbe movable to permit access to the truck or bed by being hinged alongits juncture with the front rail of the truck bed or by including centerhinges pivoting along the longitudinal axis of the truck bed to provideaccess into the truck bed from either the left side of the truck, theright side of the truck or both. Given the likelihood of haulingvaluable cargo in the truck bed, the tonneau cover must also include alocking feature in order to be locked to provide a reasonable degree ofsecurity.

Structurally, the cover must be strong and dimensionally stable. Sincethe cover will be subjected to typical ambient extremes of temperatureas well as heating from the sun and weight from heavy snow or an objectplaced thereupon, it must exhibit exceptional strength and ruggedness.

Cosmetically, the product is demanding as well since the product finishmust accept paint and result in a surface appearance rivaling that ofpainted sheet metal in order to be acceptable to purchasers.

Last of all, given the size of such tonneau covers, typically four feetby six feet (1.22 m by 1.83 m) and frequently larger, it is necessarythat the issue of total weight be considered and addressed in order tonot adversely impact the overall vehicle weight and fuel economy of thevehicle.

All of the foregoing requirements are addressed by the method andresulting product described more fully below.

SUMMARY OF THE INVENTION

A method of fabricating composite vehicle panels includes the steps offorming a first, upper panel having a depending peripheral lip, forminga second, lower panel of a laid up woven mat or strips of a fibrousmaterial such as fiberglass or carbon fibers and a plastic resin to forma corrugated panel having a depending peripheral lip, placing anadhesive on the raised portions of the corrugations and the peripherallip of the second panel and securing the panels together at thecorrugations and about their peripheral lips. An elastomeric channel maybe disposed over the adjacent ends of the lips and functions as a bumperand weather strip. The product produced by this method is also disclosedand claimed.

Thus it is an object of the present invention to provide a method offabricating composite vehicle panels.

It is a further object of the present invention to provide a method offabricating composite vehicle panels having a lower panel including aplurality of corrugations which are secured by an adhesive to an upperpanel.

It is a still further object of the present invention to provide amethod of fabricating composite vehicle panels which are securedtogether about their peripheries.

It is a still further object of the present invention to provide aproduct manufactured in accordance with the disclosed process.

Further objects and advantages of the present invention will becomeapparent by reference to the following description of the preferredembodiment and appended drawings wherein like reference numbers refer tothe same component, element, or feature.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a composite panel according to thepresent invention utilized as a tonneau cover for the bed of a pickuptruck;

FIG. 2 is an enlarged, fragmentary, sectional view of a composite panelaccording to the present invention utilized as a tonneau cover, takenalong line 2-2 of FIG. 1;

FIG. 3 is an enlarged, fragmentary, sectional view of upper and lowermold segments illustrating the production of a first or upper panelaccording to the present invention;

FIG. 4 is an enlarged, fragmentary, sectional view illustrating theapplication of plastic resin or binders to fibers or a fibrous mat toproduce a second or lower panel according to the present invention;

FIG. 5 is an enlarged, fragmentary sectional view illustrating theapplication of adhesive to the second or lower panel according to thepresent invention;

FIG. 6 is an enlarged, fragmentary, sectional view of two mold segmentsillustrating the final fabrication step of a composite vehicle panelaccording to the present invention; and

FIG. 7 is an enlarged, fragmentary, sectional view of a completedcomposite vehicle panel according to the present invention in a moldassembly.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now to FIGS. 1 and 2, a composite vehicle panel is illustratedand generally designated by the reference number 10. The compositevehicle panel 10 is generally referred to as a tonneau cover but may beone of several different vehicular panels such as a floorboard, a doorpanel, a roof panel or other generally planar body panel for use on orwith a motor vehicle such as a pickup truck 12. If a tonneau cover, thecomposite panel 10 is fitted over the open top of a truck bed 14 havinga pair of opposed, spaced apart sidewalls 16 defining horizontal,longitudinally extending rails 18. The sidewalls 16 are connected by afront wall (not illustrated) and a horizontal bottom panel (also notillustrated). The pickup truck 12 also includes a tailgate assembly 20and a cab 22. It will be appreciated that the pickup truck 12illustrated is conventional and representative of a broad range ofpickup trucks and crossover and other vehicles having an exterior cargobed.

Referring now to FIG. 2, the composite vehicle panel 10 includes a firstor upper panel 30 having a central planar surface 32 and a peripheraldepending flange or lip 34 which extends about the periphery of thecentral planar surface 32 and downwardly therefrom. The compositevehicle panel 10 also includes a second or lower panel 40 which definesa plurality of elongate ribs or corrugations 42 having raised elongatesurfaces 44 and a depending peripheral flange or lip 46 which extendsabout the entire periphery of the panel 40. The inside dimensions of thefirst or upper panel 30 adjacent the terminal portion of the peripheraledge or lip 34, i.e., the length, width and radiused corners arepreferably equal to the outside dimensions adjacent the terminal portionof the peripheral lip 46 of the second panel 40. A bead of adhesive 48resides between and secures the raised elongate surfaces 44 of theelongate corrugations 42 as well as the inner surface of the peripherallip 34 and the outer surface of the peripheral lip 46 to one another asillustrated. Preferably, a U-shaped elastomeric channel 50 is disposedover the adjacent edges of the lips 34 and 46. Both an interference fitand the adhesive 48 retain the U-shaped channel 50 on the lips 34 and46. The U-shaped channel 50 functions as a cosmetic feature, a bumper tocushion contact with the rails 18 of the truck bed 14, and as a weatherseal between the tonneau cover 10 and the rails 18.

Turning now to FIGS. 3, 4, 5, 6 and 7, the steps of fabricating andassembling the composite vehicle panel 10 will now be described. Turningfirst to FIG. 3, a conventional thermoforming die having a first orlower female mold segment 52 and, optionally, a second or upper matchingmale mold segment 54 are utilized. Whether the second or upper matchingmold segment 54 is utilized or the upper panel 30 is vacuum formedagainst only the first or lower mold segment 52 is determined by thecharacteristics of the material being formed and the desired amount ofdetail on the panel 30. The lower female mold segment 52 preferablyincludes a plurality of vacuum passageways 56 which communicate from themold surface of the mold segment 52 to a plenum 58 which is defined by aplenum wall 60 on the back side of the female mold segment 52. A vacuumpump 62 draws a partial vacuum in the plenum 58 such that air is drawnthrough the passageways 56 and the panel 30 is drawn into intimatecontact with the surface of the female mold segment 52. Assisting suchaccurate thermoforming is the optional male mold segment 54 which ismoved into intimate contact with the face of the panel 30 opposite thefemale mold segment 52. When the panel 30 has sufficiently cooled, themold segments 52 and 54 are moved apart and the panel 30 is removed. Thepanel 30 may be high density polyethylene (HDPE), thermoplastic olefin(TPO) or other suitably rugged and dimensionally stable thermoplasticmaterial. It should be understood that the panel must be at an elevatedtemperature of several hundred degrees Fahrenheit before being placed inthe mold segments 52 and 54. This may be achieved by utilizing thematerial promptly after it was extruded from a production extrusionmachine (not illustrated) or reheating the panel 30 if it is at ambienttemperature because it has been allowed to cool after its extrusion.

Referring now to FIG. 4, the second or lower panel 40 is fabricated in afemale mold or die 66 having a mold cavity surface 68 corresponding tothe desired shape and configuration of the second or lower panel 40. Assuch, the female die 66 defines a plurality of elongate, parallelcorrugations 72 and an oblique wall 74. A fibrous layer, strips, or amat 78 of, for example, fiberglass or random strands of fiberglass,carbon fiber or other stable, fibrous reinforcing material is placedupon the mold surfaces 72 and 74. A single or multiple component sprayhead 80 is then translated over the surface of the female die 66, eithermanually or through the agency of a mechanical or robot arm (notillustrated) to apply suitable plastic or resin binder 82 to the fibrouslayer or mat 78. If desired, multiple layers of fibers 78 and of plasticor resin binder 82 may be laid upon the female die 66. After anappropriate time, the second or lower panel 40 may be removed from thefemale die 66 and after suitable drying or curing, the second or lowerpanel 40 is ready for assembly.

Referring now to FIG. 5, the adhesive 48 is preferably applied directlyto the raised elongate surfaces 44 of the corrugations 42 by anelongate, horizontal adhesive distributing header 86 having a pluralityof nozzles 88 spaced apart at distances equal to the spacing of theconvolutions 42. The horizontal header 86 also includes a nozzle 92which applies the adhesive 48 to the depending lip 46. The elongateheader 86 is provided with the adhesive 48 through a flexible hose 94from a suitable pump 96 and bulk source (not illustrated).

Referring to FIGS. 6 and 7, subsequent to application of the adhesive 48to the raised elongate surfaces 44 of the convolutions 42 and theexterior of the depending lip 46, the first or upper panel 30 and thesecond or lower panel 40 are placed within mating mold segments. Thefirst or upper panel 30 is disposed within a female mold segment 102 andthe second or lower panel 40 is disposed upon a male mold segment 106.The first or upper panel 30 may be retained in the first mold segment102 by a partial vacuum provided through passageways 104 in accordancewith conventional practice. As illustrated in FIG. 7, the mold segments102 and 106 are brought together and define a mold cavity 108 having aheight which engages the panels 30 and 40 and suitably compresses theadhesive 48 and intimately bonds the first or upper panel 30 to thesecond or lower panel 40. The mold segments 102 and 106 are thenseparated and the composite vehicle panel 10 is removed therefrom.Preferably, before the adhesive 48 has hardened, the U-shaped channel 50illustrated in FIG. 2, is installed over the adjacent ends of theflanges or lips 34 and 46.

The foregoing disclosure is the best mode devised by the inventors forpracticing this invention. It is apparent, however, that products andmethods incorporating modifications and variations will be obvious toone skilled in the art of composite panels, tonneau covers andmanufacturing processes therefore. Inasmuch as the foregoing disclosurepresents the best mode contemplated by the inventor for carrying out theinvention and is intended to enable any person skilled in the pertinentart to practice this invention, it should not be construed to be limitedthereby but should be construed to include such aforementioned obviousvariations and be limited only by the spirit and scope of the followingclaims.

1. A method of manufacturing a composite panel comprising: forming a first panel having a planar center portion and a first peripheral lip; fabricating a second panel having a plurality of corrugations and a second peripheral lip; applying an adhesive to at least the corrugations of the second panel; and securing the first panel to the second panel, wherein the peripheral lip of the second panel is within the peripheral lip of the first panel with the peripheral lips in proximity.
 2. The method of manufacturing a composite panel according to claim 1, further comprising applying adhesive to the peripheral lip of the second panel.
 3. The method of manufacturing a composite panel according to claim 1, wherein the first panel is formed by thermoforming.
 4. The method of manufacturing a composite panel according to claim 1, wherein the second panel is fabricated by laying up fibrous material and coating the fibrous material with a binder.
 5. The method of manufacturing a composite panel according to claim 1, further comprising placing the composite panel over a pickup truck bed.
 6. The method of manufacturing a composite panel according to claim 1, wherein the first panel comprises a thermoformable material.
 7. A method of manufacturing a composite panel comprising: forming a first panel having a planar center portion and a first peripheral lip; fabricating a second panel having a plurality of corrugations and a second peripheral lip; applying an adhesive to the corrugations and the peripheral lip of the first panel; and securing the first panel to the second panel, wherein the peripheral lip of the second panel is within the peripheral lip of the first panel.
 8. The method of manufacturing a composite panel according to claim 7, wherein the first panel is formed by thermoforming.
 9. The method of manufacturing a composite panel according to claim 7, wherein the second panel is fabricated by laying up fibrous material and coating the fibrous material with a binder.
 10. The method of manufacturing a composite panel according to claim 7, wherein the first panel comprises a thermoformable material.
 11. The method of manufacturing a composite panel according to claim 7, wherein the second panel comprises fiberglass.
 12. The method of manufacturing a composite panel according to claim 7, further comprising installing a U-shaped channel on the peripheral lips.
 13. The method of manufacturing a composite panel according to claim 7, wherein the first panel comprises high density polyethylene.
 14. A method of manufacturing a motor vehicle composite panel for use as a tonneau cover, comprising forming a first panel having a planar center region, a lower surface and a depending flange extending about a periphery of the first panel; fabricating a second panel having a plurality of parallel corrugations having raised elongate surfaces and a depending flange extending about a periphery of the second panel; securing the lower surface of the first panel to the raised elongate surfaces of the corrugations of the second panel; and securing the depending flange of the first panel to the depending flange of the second panel, wherein the depending flange of the second panel is within the depending flange of the first panel.
 15. The method of manufacturing a motor vehicle composite panel according to claim 14, further comprising securing the depending flange of the first panel and the depending flange of the second panel by an adhesive.
 16. The method of manufacturing a motor vehicle composite panel according to claim 14, further comprising securing the raised elongate surfaces of the corrugations to the lower surface of the first panel by an adhesive.
 17. The method of manufacturing a motor vehicle composite panel according to claim 14, further comprising disposing a U-shaped, elastomeric channel around a portion of the depending flange of the first panel and the depending flange of the second panel after the depending flanges of the first and second panel have been secured to each other.
 18. The method of manufacturing a motor vehicle composite panel according to claim 14, wherein the first panel comprises a thermoplastic.
 19. The method of manufacturing a motor vehicle composite panel according to claim 18, wherein the thermoplastic is a high density polyethylene.
 20. The method of manufacturing a motor vehicle composite panel according to claim 14, wherein the second panel comprises a fiber-reinforced plastic. 